Thermal process for food enhancement

Abstract

A thermal process used to modify the moisture content and appearance of food, primarily meat, poultry and fowl, so that the resulting product will meet the USDA label requirement as “Jerky”. The process takes place in one or more enclosed insulated chambers which have temperature and relative humidity controls and reversing horizontal air flow. The process preconditions the product and also controls the application of superheated steam to the product, thereby controlling the reduction of free and bound moisture (water activity) exiting from the product. In addition, enhanced heated vapors can be added to be absorbed into the product's surface pours, thereby changing the appearance and flavor of the product and improving the end products' yields. The completed process also has the advantages of meeting lethality treatment requirements while also reducing the thermal processing time and energy associated with existing Jerky manufacturing methods.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This Application claims the benefit, for all purposes, of U.S. Provisional Application No. 61 / 744,588 filed on Oct. 1, 2012, the entire disclosure of which is incorporated herein by this reference.FIELD OF THE INVENTION[0002]This invention relates to a method of processing food products. In particular, it relates to methods of manufacturing jerky style and other shelf stable products, in an industrial or commercial application. The process could also be used on other, non-shelf stable, food products.BACKGROUND OF THE INVENTION[0003]Jerky is a food product that is manufactured under the guidelines of the USDA's public health agency, the Food Safety and Inspection Service (FSIS). It is manufactured for both human and animal consumption. The generally-accepted definition of jerky is a shelf stable (not requiring refrigeration), nutrient-dense, whole-muscle product. It can be marinated or not and sliced or ground. For manufacturing, it is norm...

AI Technical Summary

Benefits of technology

The present invention is about using superheated steam to release moisture from jerky products. This process can destroy any pathogens, improve the appearance and flavor of the jerky, and control the yield during the process. The invention aims to create a better yield, better appearance and flavor, reduced processing time, better shelf life, less energy consumption, less space in manufacturing facilities, and safer product.

Problems solved by technology

If these steps (results) are not accomplished, then the product cannot legally be labeled jerky.

If the airstream cannot surround the product uniformly, the drying will be detrimentally affected, which leads to under or over drying and yield issues as well as food safety issues (Lethality).

This process can also cause case hardening of some surfaces, thereby trapping moisture.

Since the jerky is laid flat, it impedes the airflow and non-uniform product is the result.

Other issues occur during the initial heating step with the high relative humidity set point (the lethality step).

The product, being colder than the airstream, has a lower dew point than the atmosphere and, therefore, condensation occurs on the product's surface creating more moisture to be removed, as well as discoloration (blanching).

This process also is in the presence of oxygen (which is a requirement of bacteria and mold growth) adding to the safety issues.

These issues increase the drying process and extend the total processing time by approximately 25%.

Images